Composite materials

ABSTRACT

A rigid composite material based on metal particles and a polymer binder present in an amount of between 5 and 20% by volume and adapted for use in the production of precision components.

United States Patent [191 Meyer 1 1 Dec. 2, 1975 1 COMPOSITE MATERIALS [75] Inventor: Rene Meyer, Grenoble, France [56] References i [73] Assignee: Ugine Carbone, Grenoble, France UNITED STATES PATENTS 3,341,642 9/1967 Mahar ct al. 264/111 X [22] Filed: May 20, 1974 Appl. No.: 471,475

Foreign Application Priority Data May 17, 1973 France 73.17847 U.S. Cl 264/111; 264/122 Int. Cl. B22F 3/00 Field of Search 264/1 1 l, 122

Primary ExaminerLewis T. Jacobs [57] ABSTRACT A rigid composite material based on metal particles and a polymer binder present in an amount of between 5 and 20% by volume and adapted for use in the production of precision components.

6 Claims, No Drawings COMPOSITE MATERIALS This invention relates to a new composite material based on metal powder and plastics material.

It has previously been proposed to manufacture highprecision mechanical components from a metal/- polymer composite material. Thus, bearings have been manufactured from so-called charged polymers in which the proportion of polymer is of the order of 60 to 70% by volume, the material having the characteristics of a plastics material, as reflected in particular in its limited hardness.

According to US. Pat. No. 3,300,329, metal particles are coated with plastics material. Components are manufactured by pressure molding where the proportion of polymer is high.

It is specified that the coated particles, suitable for pressure molding, contain from 10 to 80% by weight of polymer. When the proportion of polymer is low, the coated particles are only suitable for the production of pigments. This is confirmed by the examples, in which a mixture is used which contains 10% by weight of polymer to 90% of copper powder, corresponding to a proportion by volume of the order of 45% polymer to 55% copper. In another example, the mixture used contains 42% by weight polymer to 58% aluminum pow der, corresponding to a proportion by volume of 62% of polymer to 38% of aluminum.

The present invention relates to a composite metal/- polymer material which can be used for manufacturing precision structural components, and to a simple process for manufacturing precision components of this material.

The composite material according to the invention is a rigid, agglomerated material consisting essentially of an intimate mixture of metal particles and plastics material with a proportion of voids of less than distinguished by the fact that the volume of the plastic binder amounts to between 5 and 20% of the total volume, preferably to between and of the total volume.

The metal phase is made up of compact, non-porous particles of at least one metal combining high mechanical strength with high ductility before compression.

The metals used are, for example, iron, extra-soft steel, malleable cast iron, aluminum, copper and their alloys. Those metals, which can readily be cold-worked under the conditions, onto which the components are manufactured (for example iron, copper) enable a higher degree of hardness to be obtained. 7

The binder phase consists of at least one polymer which shows high mechanical strength and adheres firmly to the particles of the metal phase.

The products according to the invention have a com pact texture of metal particles bonded together by a film of plastics material. In addition, the plastics material almost completely fills the voids between particles.

This texture is remarkable in that it comprises only a low proportion by volume of plastic binder within the critical limits of 5 to ofthe total volume. It has surprisingly been found that the curves representing the variations in the tensile strength and flexural strength of the composite materials, cold-molded under high pressure and then consolidated by baking, based on metal powder and plastic binder, as a function of the proportion by volume of binder, showed maxima for values proportional to the volume of binder situated within these limits.

It has also surprisingly been found that, in the case of the composite materials according to the invention, the ratio of the Brinell hardness HB of the end product to the elastic limit in N/mm of the metal of the particles is distinctly higher than in the case of conventional sintered metals, in particular low alloy steels, where it is of the order of 0.3. The subject matter of the invention thus has a remarkable hardness in relation to its resistance. This is especially significant when the manufacturing conditions have caused a high rate of crushing of the metallic granules.

These properties will be illustrated by the following examples:

In view of the high volumetric metal content and the compactness of the product, it has a considerable electrical and heat conductivity, and a rather high modulus of elasticity.

The subject matter of the invention may also contain one or several additional materials, to obtain particular core or surface qualities, for example, due to a hard substance to increase the friction coefficient, or due to a solid or liquidlubricant to provide antifriction properties, or even by addition of a pigment to change the color.

To manufacture this material, the applicant has perfected a simple method which also is part of the invention and which consists of preparing an intimate mixture of metal particles and binder in volume proportions of the finished product, compressing this mixture at ambient temperature in a closed die, at a pressure at least equal to twice the limit of elasticity of the metal of the particles, removing the material from the mold, heating the product thus obtained to a temperature sufficient to make it fluid, and possibly polymerize the plastic binder, and allowing it to cool.

In cases where a powdered resin is used, the particles preferably have a gain size of less than 50 min order to obtain, in the mixture, a uniform distribution of this polymeric phase around the metal particles. In general,the particles have a larger grain size in thb range from 300 to 500 t. It is of advantage to use a powdered resin because the electrostatic attraction, between the particles of the mixture. promotes uniform distribution and prevents segregation during application of the process.

In cases where a dissolved resin or liquid resin is used, the metal particles are coated by kneading under heat, the solvent being eliminated by evaporation. The plastic binder is selected by testing both depending upon the type of metal powder and upon the required mechanical properties. The resin is, preferably, a thermosetting resin (epoxy resins, phenolic resins, polyesters, polyimides, etc.) which is introduced into the mixture in partly polymerized form and which liquefies on heating before ultimately hardening.

The grain distribution and geometry of the particles of the mixture should be such that compressibility (represented by the density of the compact after application of a given pressure) is as high as possible, so as to obtain a compact material.

The cleanness of the metal particles, the absence of oxidation, and a certain amount of surface roughness, all promote bonding between metal and plastic in the end product.

The proportion by weight of plastic binder in the starting mixture corresponds to a proportion by volume of 5% to 20% in the end product; in other words, it is, for example. of the order of 0.8 to 3.8% by weight for a mixture of iron powder (density of iron 7.8) and a 3 resin of density 1.2, and of the order of 2.2 to 10% by weight for a mixture of aluminum powder (density of aluminum 2.7) and a resin of density 1.2.

Compression is carried out with presses and tooling The material according to the invention can also be produced by preparing a compressed blank of metal powder, as by impregnating it with liquid resin, followed by baking. Unfortunately, this process is not as commonly used in powder metallurgy. The pressure, 5 practical as the process previously described. amounting to at least twice the elastic limit of the me- The material according to the invention has the foltallic material, is substantially in the range from lowing advantages over plastics materials filled with 100-800 N/mm and even 1,000 Newton/mm? Any inmetal powders: crease in pressure, under otherwise the same condibetter mechanical characteristics; tions, is accompanied by an increase in hardness and an greater hardness and, hence, higher resistance to increase in strength. This is attributable to the increase wear by friction or rolling; in the density of the compact and to the more intense a lower coefficient of expansion similar to that of the cold-working of the metal particles. To facilitate comstarting metal; pression and, subsequently, ejection of the compact, it better thermal conductivity; is of advantage to lubricate the spindles and the walls of metallic appearance; the mold. It is also possible to add to the mixtures of lower material costs. powders a small quantity (a few tenths of a percent) of In comparison with sintered metals, the material acfine particles of a solid lubricant or of a highly volatile cording to the invention is more resistant to corrosion, lubricant capable of being eliminated through the open has no open porosity, shows high electrical resistivity pores of the compact at the beginning of heating. which can be adapted ,to meet requirements and The components released from the mold are air greater dimensional precision. baked in an oven for a period and at a temperature ap- The following examples illustrate the process for propriate both of melting (thermoplastic binder) and to manufacturing the materials according to the invention polymerization (thermosetting binder) of the plastic and their qualities. phase. In most cases, baking lasts for 30 minutes to l hour at a temperature in the range from 150 to 250C EXAMPLE 1 for conventional resins. Inside the compact, the poly- Commercial grade, highly compressible, atomized mer liquefies and forms a film between the metal partiand annealed iron powder, with a grain size of less than cles which fills most of the voids by capillary action 150 p. (type Hoganas ASC 100-29), is mixed dry for a without any surface exudation, because it is only used period of 60 minutes with various proportions of powin a small quantity. dered epoxy resin with a grain size of less than 50 p.

Rigid, precision components, identical in shape and (type Scotchcast 265). The resin was checked for regusize with the compact before heating, are obtained lar distribution. The mixture of powders was comafter cooling. This process is particularly suitable for pressed under a pressure of 800 Newton/mm in floatthe production of small precision moldings in large ing molds with walls lubricated with stearic acid, to numbers. form flat bars measuring 60 X 10 X 5 mm, standard ten- The properties of the material according to the insile test specimens. The compacts had aresidual porosvention can be defined in advance, within a fairly wide ity of 4%. On being released from the mold, the moldrange, by varying the type and proportions of the conings were found to have undergone a reduction of stituents of the mixture, the shape of the particles, and 0.25% in their horizontal dimensions. They were baked the compression rate, on the basis of the principles disin air for 20 minutes at 200C. The horizontal dimencussed above. Baking at a moderate temperature presions of a series of identical moldings were found to vents deformation and contraction reactions between vary by, at most, 0.02 mm over mm. The moldings metal phase and additives, if any, and oxidation of the had a smooth surface and did not show any signs of metal. 45 rusting after exposure to the atmosphere for several The process according to the invention, which is exdays. tremely simple and inexpensive, can be applied to With various proportions by weight of resin in the inimetal powders which are not suitable for sintering. tial mixture, the following characteristics were obtained in the end products:

Mixture End product Weight Volume Mass Ten- Elecof of by l-Iardsile trical Resil- Flexural resin resin volume ness strength resistience strength g/cc HB N/mm (l m .I/cm N/mm 0 0 7.4 105 1% to -10 -0.5 20 to 40 0.4 2.5 7.3 100 6?) 0.02 0.8 120 0.7 4.5 7.25 95 0.03 0.9 160 1 6.4 7.2 0.03 1 190 1.5 9.2 7.0 90 0.10 1.4 210 2.3 13.4 6.75 85 0.8 1.6 220 not not 3 17.5 6.5 80 100 measured measured 200 4 21 6. 7s 95 40 1.6 190 moldings not not 5 26 heavily 60 85 measured measured deformed not not 10 42 S0 70 measured measured I40 100 100 1.2 35 35 00 -1 70 An optimum zone for strength and resilience is found to exist on either side of approximately 2% by weight of resin, i.e. 12% by volume of the end product. Where there is equality of properties, it is of advantage to manufacture the material which contains the least resin because it will be harder.

EXAMPLE 2 Commercial grade aluminum powder (grain size less than 150 ,u) is mixed dry for a period of 60 minutes with various proportions of powdered epoxy resin with a grain size of less than 50 p. (type Scotchcast 265).

The mixture is compressed at ambient temperature under a pressure of 150 to 300 N/mm in a floating mold with walls lubricated with stearic acid, to obtain mechanical test specimens. Residual porosity is less than 5% after compression under 150 Nlmm and less than 2% after compression under 300 N/mm The moldings are baked in air for minutes at 200C.

The results obtained are set out in the following table:

Once again, there is an optimum zone in the composition of the end product for maximum mechanical strength, i.e. between 3% and 9% by mass of resin or approximately 5% to 20% by volume. Application of the highest compression ives more favorable mechanical properties although, eyond 6% by mass, the components are deformed throu h the exudation of resin during bakin In this case, t e resin content has to be limited to 6 o by weight.

I claim:

1. A process for manufacturing a rigid composite material, comprising preparing an intimate mixture of particles of non-porous metal of high mechanical strength and high ductllity and an organic thermosettin or thermoplastic resinous plastics material which has igh mechanical strength and strong adhesion to the metal particles in a proportion by volume corresponding to 5 to 20%, molding the resulting mixture in a closed mold under a pressure of at least twice the elastic limit of the metal, opening the mold, heating the compact thus ob tained to a sufficiently high temperature to melt and, optionally, polymerize the plastic binder, followed by cooling.

2. A process as claimed in claim 1, wherein compression is sufficient to subject the metal particles to coldworking.

3. A process as claimed in claim 1, wherein the molding pressure is between and 1000 Nlmm 4. A process as claimed in claim 1, wherein the binder is a thermosettmg resin.

5. A process as claimed in claim 1 wherein the binder is introduced into the mixture in powder form.

6. A process as claimed in claim 1, wherein the mixture consists of metal particles coated with a liquid binder. 

1. A PROCESS FOR MANUFACTURING A RIGID COMPOSITE MATERIAL, COMPRISING PREPARING AN INTIMATE MIXTURE OF PARTICLES OF NONPOROUS METAL OF HIGH MECHANICAL STRENGTH ANDHIGH DUCTILITY AND AN ORGANIC THEMOSETTING OR THERMOPLASTIC RESINOUS PLASTICS MATERIAL WHICH HAS HIGH MECHANICAL STRENGTH AND STRONG ADHESION TO THE METAL PARTICLES IN A PROPORTION BY VALUME CORRESPONDING TO 5 TO 20%, MOLDING THE RESULTING MIXTURE IN A CLOSED MOLD UNDER A PRESSURE OF AT LEAST TWICE THE ELASTIC LIMIT OF THE METAL, OPENING THE MOLD, HEATING THE COMPACT THUS OBTAINED TO A SUFFICIENT HIGH TEMPERATURE TO MELT AND, OPTIONALLY, POLYMERIZE THE PLASTIC BINDER, FOLLOWED BY COOLING.
 2. A process as claimed in claim 1, wherein compression is sufficient to subject the metal particles to cold-working.
 3. A process as claimed in claim 1, wherein the molding pressure is between 100 and 1000 N/mm2.
 4. A process as claimed in claim 1, wherein the binder is a thermosetting resin.
 5. A process as claimed in claim 1 wherein the binder is introduced into the mixture in powder form.
 6. A process as claimed in claim 1, wherein the mixture consists of metal particles coated with a liquid binder. 